Waste Pre and Co-processing in Cement Kilns: Concepts and Benefits

Transcription

1 Waste Pre and Co-processing in Cement Kilns: Concepts and Benefits Satendra Singh Geocycle Kymore Holcim Technology 2014 Ltd

2 Agenda 1. Geocycle 2. Waste Management Hierarchy 3. Concept of Pre-processing 4. Concept of Co-processing 5. Pre-processing system design 6. Co-processing system design 7. Pre-processing facility at Kymore 8. Fire fighting facility at Geocycle PCPF 9. Questions and Answers 2

3 Geocycle Geocycle is waste management brand of Holcim, one of the world s leading supplier of construction materials Geo means earth in Greek, while Cycle calls to mind the cycle of life. Geocycle refers to our ability to convert waste into a safe, useable resource

4 Waste Management Hierarchy 3R+C Main drive: LCA 1. Reduce 2. Reuse When prevention / reuse is not feasible 3. Recycle - Re-processing Recycling of end-of life cementitious products When re-processing is not feasible 4. Resources Co-processing in existing EII s Process specific guidelines Pre-processing is key When Co-processing is not applicable 5. Wastes disposal activities For organics: Incineration - Wastes to energy programs - Energy efficiency is key For minerals: Land filling

5 Concept of Pre-processing Pre-Processing is making the waste similar to fuel in properties by physical changes like size reduction, separation, segregation and preparing homogeneous mixture Benefits: Reduce the waste volume Homogenize the waste Makes waste similar to fuel in properties Reduces the impacts on process Creates regional job in waste collection, pretreatment, etc.

6 Concept of Co-processing Co-Processing is the use of waste materials/pre-processed waste in RII s (Resources Intensives Industrial processes) such as cement, lime, steel, glasses, power generation etc instead of using fossil fuels & natural resources. Benefits: Upgrades waste management within the waste hierarchy Reduces global environmental impacts Decreases (largely) the costs of waste management Creates regional job in waste collection, pretreatment, etc. Is a zero-emission technology

7 Sources of Material for Pre and Co-processing 26 categories of industries that are sources of co-processable material worldwide have been identified by Holcim 1. Agricultural Production - Crops 2. Agricultural Production - Livestock 3. Agricultural Services 4. Metal Mining 5. Coal Mining 6. Oil and Gas Extraction 7. Mining and Quarrying of Nonmetallic Minerals 8. General Building Contractors 9. Heavy Construction Contractors 10. Special Trade Contractors 11. Food and Kindred Products 12. Lumber and Wood Products, Except Furniture 13. Furniture and Fixtures 14. Paper and Allied Products 15. Chemicals and Allied Products 16. Petroleum Refining & Related Industries 17. Rubber and Miscellaneous Plastic Products 18. Leather and Leather Products 19. Glass Products 20. Primary Metal Industries 21. Fabricated Metal Products 22. Indus. and Comm. Machinery and Computers 23. Electronic & Electrical Equipment 24. Transportation Equipment 25. Photographic Equipment and Supplies 26. Electric, gas, and sanitary services EU Commercial Synergies - Discussion,

8 But All Wastes Are Not Co-processable List of Banned Wastes Asbestos containing waste Anatomical hospital waste Bio-hazardous waste Electronic scrap Entire batteries Explosives High concentration cyanide waste Mineral acids Radioactive waste Unsorted municipal solid waste EU Commercial Synergies - Discussion,

9 Waste & Sustainability: The Challenge IMPACTS ON Inputs Process Output Emission BENEFITS Mixing/blending of wastes with varying physical and chemical properties Process wastes as per the capability of process and feed points (keep the limiting constituents under control) Produce cement as per the prescribed BIS standards

10 Reduction of GHGs Co-processing and Incineration Reduction in CO2 Emissions Co-processing and Landfill Prevention of CH4* Emissions * CH4 has 21 times more global warming potential than CO2 EU Commercial Synergies - Discussion,

11 Pre-Processing Platforms at a glance Waste Pre -processing Processed Waste EU Commercial Synergies - Discussion,

12 Pre-Processing System Design Equipment Arm Handler and Pay loader Shredder and Belt conveyors Magnetic Separator Star Screen

13 Co-Processing System Design Equipment Walking Floor Chain Belt Conveyor Weigh Feeder Long Belt Conveyor Sacrificial belt Conveyor Rotary Air Lock Safety Shut off Gate Feed chute at Calciner

14 % TSR AFR at ACC Kymore %TSR at ACC Kymore 1. RICE HUSK 2. SOYA HUSK 3. GRUM HUSK 4. SAW DUST 5. COWDUNK 6. PLASTIC WASTE 7. HUL TRADE REJECT 8. RDF 9. SRF WASTE 10. NIVIA WASTE 11. NESTLE TRADE REJECT 12. ETB BIO SLUDGE 13. SPENT CARBON 14. PAINT SLUDGE 15. CARBON BLACK 16. CADBOURY LAMINATES & TRADE REJECTS % TSR Vs YEARS % TSR % TSR after PCPF YEARS 17. OZONE DEPLETING SUBSTANCES ODS (2012) FIRST TIME IN INDIA ACC KYMORE HAS COPROCESSED ODS WITH SPECIALLY DESIGNED FEEDING SYSTEM IN CEMENT KILN

15 Pre-Processing Facility at ACC Kymore

16 Fire Fighting facility at PCPF Kymore Fire water tank M3 Detection System - UV/IR Flame detectors and LHS cables Suppression System Hydrant and Hose real System Medium velocity Water Spray System (MVWS) Low expansion foam system Early suppression fast response (ESFR) type sprinkler system Portable Fire Extinguishers

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